### Ap **pendix A : Example Calculation of Exhaust Flow Rate, Percent Moisture and Percent Oxy** **gen**

C 70.6 Excess Air (%) 15 H 2 22.7 Temperature (std.) 350

N 2 5.7 Heating Value (Btu/lb) 22027
S

-- Ash

-- O 2 1

**Calculate Theoretical Oxy gen Requirement in Combustion A** **ir:**

**Element % by**  **weight Molecular weight**  **Mole/100 lb of fuel=%/MW**  **Resulting Product**  **Required**

**moles of Ox/ 100**  **lb fuel** C 70.6 12 5.9 CO2 5.9 H 2 22.7 2 11.4 H2O 5.7
N 2 5.7 28 0.2
O 2 1 32 0.03 -0.03 Total 100 11.6

22027 Btu/lb fuel x 100/100 lb fuel x MMBtu/1000000 Btu = 2.2MMBtu/ 100 lb fuel

15 = 100 x (O2 - 11.6)/11.6

O2 = 13.3 molesO2/100 lb fuel **Material A naly** 

**sis A verage Values for Natural Gas from Steam**  **Fuel Values and Combustion Unit As**  **sumptions**

**Calculate Heat Content of Natural Gas per 100 lb of fuel**

**Solve for Required Moles of O2/100 lb fuel at 15% excess air**

### Ap **pendix A : Example Calculation of Exhaust Flow Rate, Percent Moisture and Percent Oxy** **gen**

Ratio of N2 to O2 in the Atmosphere - 3.77 [moles N2 to moles O2]

N2 = 13.3 moles O2/100 lb fuel x 3.77 moles N2/1.0 mole O2

N2 = 50.1 moles/100 lb fuel

**Calculate Exhaust Totals Element**  **Basis Exhaust (moles/100 lb fuel)**  CO2 5.9 C 5.9 H20 11.4 H2 11.4 O2 13.3 - 11.6 1.7 N2 0.2+50.1 50.3 **Total** 69.3

**Calculate Exhaust Volume acf/lb fuel** Pressure x Volume = Moles x Constant x Temperature Exhaust Volume = Moles x constant x Temperature / Pressure Constant = 10.73 psia-ft3/lb-mole-deg R Temperature Conversion deg R = deg F + 460

**Calculate Exhaust Volume acf/MMBtu** Exhaust Volume = Volume in acf/lb fuel x Heat Content per 100 lb fuel Exhuast Volume = 409 acf / lb fuel x 100 lb fuel / 2.2 MM Btu = 18590 acf/MMBtu at 15% excess air

**Calculate Exhaust Flow Rate from Exhaust Volume using Example Capacity of 5 MMBtu/hr**  Exhaust Flow rate = Exhaust Volume in acf/MMBtu x Capacity in MMBtu/hr x 1 hr/60 minutes Exhaust Flow Rate = 18590 acf/MMBtu x 5 MMBtu/hr x 1/60 = 1549 acfm

**Calculate Percent Moisture in Exhaust** Exhaust Moisture (%) = (11.4 moles H2O/100 lb fuel) / 69.3 total moles/100 lb fuel x 100% = 16.5 %

**Calculate Percent Oxy gen in Exhaust**  Exhaust Moisture (%) = (1.7 moles O2/100 lb fuel) / 69.3 total moles/100 lb fuel x 100% = 2.5 %

**Sources:**Exhuast Volume = 69.3 lb-moles / 100 lb fuel x 10.73 psia-ft3/lb-mole-deg R x (1/14.7psia) x (350 deg F + 460) = 409 acf / lb fuel **Calculate Moles of N2/100 lb fuel in Combustion A ir** 

Alvis, Jeanette, C. Burlew and R. Oommen, ERG. Development of Model Units for the Industrial/Commercial/Institutional Boilers and Process Heaters National Emision Standards for Hazardous Air Pollutants. October 2002.

### Appendix B: Fabric Filter Costs
**Parameters/Costs Equation** 

A. Parameters 1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr) 2. Annual operating hours, hr/yr (H) used Boiler Survey data as input 3. Exhaust gas flow rate, dscfm (Q) calculated per boiler, see Section 2.0 of the memo. 4. PM concentration, gr/dscf (PM) calculated baseline emission factor for PM (lb/mmBtu)*C*(7000/60)/Q 5. W ater vapor in gas (% by weight) (%M) estimated per boiler, see Section 2.0 of the memo. a. lb/min = Q / (385 ft3/lb-m ol) x (29 lb/lb-mol) x %M b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3/lb-m ol)

a. Dry gas from boiler, Btu/lb air = [7.010 x (300 ° F - 77 ° F) - 7.554 x (1800 ° F - 77 ° F)] / (29 lb/lb-mol)

b. W ater vapor from boiler, Btu/lb water vapor = [8.154 x (300 ° F - 77 ° F) - 9.215 x (1800 ° F - 77 ° F)] / (18 lb/lb-mol)

c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x (60 min/hr) x H] + [(Btu/lb water vapor) x Q x (0.00753 lb water vapor/ft3) x (60 mi n/hr) x H] d. Cooling water i. Heat of vaporization at 77 ° F, Btu/lb 1050 ii. Sensible heat for vapor, Btu/lb 85 iii. Total, Btu/lb water 1135 7. Cooling water evaporated, lb/yr a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change (cooling water, Btu/lb)] b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3/lb-mol) / (H * 60 min/hr) 8. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from incinerator, scfm) + (water vapor added in quench, i.e., cooling water evaporated, scfm)] x [(300 ° F + 460 ° F)/528 ° R] 9. Operating labor rate, $/hr (LR) 51.26 10. Electricity cost, $/kW h (EC) 0.069981 11. W ater cost, $/gal (W C) 0.000559 12. Compressed air cost, $/1,000 ft3(CAC) 0.31 13. Dust disposal cost, $/ton (DDC) 42.14 14. Capital recovery factors = [i x (1 + i) a] / [(1 + i) a - 1], where i = interest rate, a = equipment life

a. Bag CRF, 2-yr life, 7% interest b. Cage CRF, 4-yr life, 7% interest c. Equipment CRF, 20-yr life, 7% interest

d. Duct CRF, 20-yr life, 7% interest 15. Cost index a. 2008 525.4 b. 1989 357.5 16. Retrofit Factor 1.4 17. Gas transport velocity, ft/min (ut) assigned constant, 3000 18. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2 19. Number of Duct Lines, (ND) if Q < 154042 acfm =1 if Q > 154042 acfm = Q/154042 acfm 20. Length of ductwork (L) assigned constant, 500 21. # of elbows per length of duct (Ne/Ld) assigned constant, 0.02 22. Fan coefficient (af) assigned constant, 22.1 23. Fan Diameter, inches (Df) assigned constant, 36.5 24. Fan exponent (b) assigned constant, 1.55

B. Total Capital Investment 1. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x (Df^b)))) 2. TCI $ = (47.0 x Q + 306,720) x (Retrofit Factor) x (525.4/357.5)+TCIduct 3. $/dscfm = $ / Q

C. Direct Annual Operating Costs, $/yr 1. Electricity = (0.746 kW /hp) x hp (0.0072 x Q + 3.20) x H x EC 2. Electricity - Ducts a. Friction loss factor for elbow (k) assigned constant, 0.19 b. Efficiency of fan (ef) assigned constant, 0.70 c. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x (ut/4016)^2) f. Electricity for Fan use, kW (Efan) =((0.000117 x Q x H x Pd)/ef) g. Cost of Electricity, $/yr =EC x Efan 3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 min/hr) x H x W C 4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR 5. Supervisory labor = 0.15 x (operating labor) 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) 7. Maintenance materials = 0.02 x TCI 8. Compressed air = AQ x (2 ft3air/1,000 ft3filtered) x (60 min/hr) x H x CAC 9. Dust disposal = (PM gr/dscf x Q x 60 min/hr x 1 lb/7,000 gr) x (1 ton/2,000 lb) x H x DDC 10. Bag replacement a. Bag cost = AQ x ($2.5/ft2 ) x (525.4/317.4) x (1.08 taxes and freight ratio)/(3.5 ft/min G/C ratio) b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2bag area)/(3.5 ft/min G/C ratio) x LR c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag replacement labor cost)] 11. Cage replacement a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2bag area) b. Cage replacement labor cost = bag replacement labor cost c. Cage replacement cost = Cage CRF x [single-cage cost (4.941+ 0.163 x 18 ft2bag area) x (number of bags) x (525.4/317.4) + (cage replacement labor cost)] 6. Enthalpy change in quench (1800 ° F to 300 ° F)

### Appendix B: Fabric Filter Costs
**Parameters/Costs Equation** 

D. Indirect Annual Costs, $/yr 1. Overhead = 0.6 x (labor + maintenance materials) 2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement cost) 4. Duct TAC a.TACductwork =TCIduct x (0.04 + CRFduct) b. Duct_cap recov =TACductwork x 0.7 c. Duct_admin =TACductwork x 0.1498 d. Duct_prop tax =TACductwork x 0.0749 e. Duct_insurance =TACductwork x 0.0749 f. Total TACduct =Duct_cap recov + Duct_admin + Duct_prop tax + Duct_insurance

E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs + Total TACduct 2. ($/yr) / dscfm = ($/yr) / Q

Sources:

3. Electricity cost: Energy Information Administration. Average Industrial Retail Price of Electricity: October 2009. 4. W ater cost: Air Compliance Advisor, version 7.5. 5. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004. 6. Dust disposal cost: NSW MA’s 2005 Tip Fee Survey 1. Cost equations: Hospital/Medical/Infectious W aste Incinerators (HMIW I) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32). 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2008 National Industry-Specific Occupational Employment and W age Estimates

## Ap **pendix C: ESP Costs**

**Parameters/Costs Equation** 

A. Parameters 1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr) 

### 2. Annual operating hours, hr/yr (H) used Boiler Survey data as input 

### 3. Exhaust gas flow rate, acfm (Q) calculated per boiler, see Section 2.0 of the memo. 

### 4. PM concentration, gr/dscf (PM) calculated baseline emission factor for PM (lb/mmBtu)*C*(7000/60)/Q 

### 5. Efficiency, % (E) =100*(1-(PM emission limit/PM)) 

### 6. Temperature (T) assigned based on fuel type, see Section 2.2.2 of the memo 

### 7. Inlet Moisutrue, % (IM) assigned constant, see Appendix C-2 

### 8. Specific Collection Area ratio (SCA) assigned based on efficiency, see Appendix C-2 

### 9. PM Migration velocity (Mv) assigned constant, see Appendix C-2 

### 10. Total Collection Place area, ft2 (TCP) =(Q/1000) x ((-508*LN(1-(E/100)))/Mv) x SCA 11. Equipment Cost of ESP, $ (EC) if TCP<50,000 =614.55(TCP)^0.6276 if TCP>50,000 =57.87(TCP)^0.8431 12. Factor to convert from FRP to other material (m) assigned constant, see Appendix C-2



### 13. Cost index a. 2008 525.4 b. 1998 389.5 14. Capital recovery factors = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipment life

Equipment CRF, 20-yr life, 7% interest Duct CRF, 20-yr life, 7% interest 15. Operating labor rate, $/hr (LR) SEE cost input summary 16. Electricity cost, $/kW h (EC) SEE cost input summary 17. Dust disposal cost, $/ton (DDC) SEE cost input summary 18. Retrofit Factor 1.4 19. Gas transport velocity, ft/min (ut) assigned constant, see Appendix C-2 

### 20. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^ 1/2 

### 21. Number of Duct Lines, (ND) if Q < 154042 acfm =1 if Q > 154042 acfm = Q/154042 acfm 22. Length of ductwork (L) assigned constant, see Appendix C-2 

### 23. # of elbows per length of duct (Ne/Ld) assigned constant, see Appendix C-2 

### 24. Fan coefficient (af) assigned constant, see Appendix C-2 

### 25. Fan Diameter, inches (Df) assigned constant, see Appendix C-2 

### 26. Fan exponent (b) assigned constant, see Appendix C-2



### B. Total Capital Investment (TCI) 1. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x (Df^b))))*(575.4/389.5)*Retrofit Factor 2. $ =3.8326 x m x EC x Retrofit Factor + TCIduct 3. $/acfm = $ / Q

C. Direct Annual Operating Costs, $/yr 1. Electricity a. Friction loss factor for elbow (k) assigned constant, see Appendix C-2 

### b. Efficiency of fan (ef) assigned constant, see Appendix C-2 

### c. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x (ut/4016)^2) d. Pressure drop through ESP, in.H2O (Pesp) assigned constant, see Appendix C-2



### e. Pressure drop of gas, in.H2O (Pg) =Pesp+Pd f. Electricity for Fan use, kW (Efan) =((0.000117 x Q x H x Pg)/ef) + 0.00194 x TCP x H g. Cost of Electricity, $/yr =EC x Efan 2. Dust disposal =0.00000429 x H x DDC x PM x Q x E 3. Labor a. If TCP < 10,000 then Of =0 b. If TCP > or = 10,000 then Of=1 c. Cost of Labor, $/yr (LC) = 0.1854 x H x LR x Of 4. Maintenance Cost, $/yr (MC) a. If TCP<50,0000 =4125 + 0.004464 x TCI b. If TCP> or = 50,000 =0.0825 x TCP + 0.00446 x TCI
D. Indirect Annual Costs, $/yr 1. Overhead = 0.6 x (LC + MC) 2. Property taxes = 0.01 x TCI 3. Capital recovery = Equipment CRF x (TCI) 4. Administrative cost =0.02 x TCI 5. Insurance =0.01 x TCI 6. Duct TAC a.TACductwork =TCIduct x (0.04 + CRFduct) b. Duct_cap recov =TACductwork x 0.7 c. Duct_admin =TACductwork x 0.1498 d. Duct_prop tax =TACductwork x 0.0749 e. Duct_insurance =TACductwork x 0.0749

## Ap **pendix C: ESP Costs**

**Parameters/Costs Equation**  f. Total TACduct =Duct_cap recov + Duct_admin + Duct_prop tax + Duct_insurance

E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs + Total TACduct 2. ($/yr) / dscfm = ($/yr) / Q

Sources: 1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 6. EPA/452/B-02-001, January 2002. 2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process Heaters National Emission Standards for Hazardous Air Pollutants, October 2002.

# Ap **pendix C: ESP Costs**

**Var COMMON DEFA** **ULTS - ESP** I I = interest rate 0.07 Ne_Ld Ne/LD = # of elbows per length of duct 0.02 L L = length of ductwork 500 ut ut = gas transport velocity , ft/min 3000

**Var DEFA** **ULTS- TOTA L A** **NNUA L COST -- ESP** 

n n = life of equipment, yrs 20 Op_ESP Op_ESP = operating hours/year 8400 CFdd CFdd = cost factor for dust disposal, $/ton 42.14111 CFlab CFlab = cost factor for labor, $/hr 51.26

Ps = **DEFA ULTS - ELECTRICITY - ESP**  CFelec CFelec = cost factor for electricy , $/kw-hr 0.06998 Pesp Pesp = pressure drop through esp, in H2O 0.38 k k = friction loss factor for elbow 0.19 Ef Ef = efficiency of fan 0.7

**DEFA ULTS - DUCTWORK - ESP**  af af = fan coefficient 22.1 b b = fan exponent 1.55 Df Df = fan diameter, inches 36.5 n_duct n_duct = life of equipment, yrs 20

**DEFA ULTS -TCI - ESP**  Fone Fone = special add-on factor 1 Ftwo Ftwo = no special add-on factor 0

m m = factor to convert from FRP to other mat. 1 Mv Mv = PM m igration velocity , cm/s 16

Sources: **ESP DEFA ULTS** 

1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 6. EPA/452/B-02-001, January 2002.

2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process Heaters National Emission Standards for Hazardous Air Pollutants, October 2002.

## Ap **pendix D: Packed Bed Scrubber**

**Parameters/Costs Equation** 

A. Parameters

1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr) 

### 2. Annual operating hours, hr/yr (H) used Boiler Survey data as input 

### 3. Exhaust gas flow

rate, acfm (AQ) calculated per boiler, see Section 2.0 of the memo. 

### 4. PM filterable baseline emission, lb/mmBtu (PMb) used Boiler Survey data as input



### 5. HCl Baseline, lb/mmbtu (HClb) used Boiler Survey data as input 

### 6. Temperature (T) assigned based on fuel type, see Section 2.2.2 of the memo 

### 7. Inlet Moisutrue, % (IM) calculated per fuel type, see Appendix D-2 

### 8. HCl Floor, lb/mmBtu (HClf) assigned based on fuel 

### 9. Efficiency (E) = 100 x (1 - (HClf/HClb)) 10. Inlet HCl Loading, lb/hr (In HCl) =HClb x C 11. Inlet PM loading, lb/hr (In PM) = PMb x C 12. Inlet HCl loading, mole fraction (In HClm) =InHCl x (T = 460) / (2958.12 x AQ) 13. Inlet PM loading, gr/acfm (InPMg) =InPM / AQ x 116.7 14. Packing Cost Factor, $/ft3 (Cp) constant, see Appendix D-2 

### 15. Scrubber Diameter Component (SDC) a. ratio of solvent density to water density (mm) defined in Appendix D-2 

### b. packing factor (Fp) defined in Appendix D-2 

### c. viscosity of liquid, lb/ft-hr (ui) defined in Appendix D-2 

### d. flooding factor (f) defined in Appendix D-2 

### e. minimum wetting rate, ft2/hr (MW R) defined in Appendix D-2 

### f. packing constant, ft2/ft3 (ap) defined in Appendix D-2 

### g. SDC '=(-0.915 - SQRT(-1.144359 -(1.188 x (LOG((mm x Fp x ((ui / 2.42) ^ 0.2) x MW R^2 x ap^2) / (12960000 x f^2 x 32.2),10)))))/-0.594 

### 16. Scrubber Diameter, ft (Ds) a. density of liquid, lb/ft3 (Dl) defined in Appendix D-2 

### b. density of gas, lb/ft3 (Dg) defined in Appendix D-2 

### c. Ds =(SQRT((240 x Dg x AQ x 10^SDC)/(MW R x Dl x ap x PI x SQRT((Dg/Dl))))) 

### 17. Height of packing, ft (Hpack) a. packing constant (BBB) defined in Appendix D-2 

### b. packing constant (X) defined in Appendix D-2 

### c. HpackA = X x (240 x Dg x AQ) / (PI x Ds^2) 

### d. packing constant (g) defined in Appendix D-2 

### e. HpackB = (MW R x D x ap)^g 

### f. viscosity of gas, lb/ft-hr (ug) defined in Appendix D-2 

### h. diffusivity of gas, ft2/hr (Dfg) defined in Appendix D-2 

### i. HpackC = SQRT(ug/(Dg*Dfg) 

### j. packing constant (BB) defined in Appendix D-2 

### k. HpackD =((MW R x Dl x ap)/ui)^BB 

### l. liquid diffusivity, ft2/hr (Dfl) defined in Appendix D-2 

### m. HpackE = SQRT(ui/(Dl x Dfl)) 

### n. pollutant mole fraction exiting scrubber(Out HClm) =In HClm x (100-E)/(100 - (In HClm x E))



### o. adsorption factor (AF) defined in Appendix D-2 

### p. packing constant (t) defined in Appendix D-2 

### q. Hpack =Ln(In HClm/Out HClm) x (HpackA/HpackB^BBB) x HpackC + 1/AF x (t x HpackE^BB) x HpackE 

### 18. Cost factor for pump, $/gpm (Cfpump) defined in Appendix D-2 

### 19. Factor to convert FRP to another material defined in Appendix D-2 

### 20. Cost Index a. 2008 525.4 b. 1998 389.5 21. Capital recovery factor (CRF) = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipment life

Equipment CRF, 20-yr life, 7% interest Duct CRF, 20-yr life, 7% interest 22. Operating labor rate, $/hr (CFlab) $51.26 23. Electricity cost, $/kW h (CFelec) $0.069981 24. W ater cost, $/gal (CFw) $0.00059889 25. W astewater disposal cost, $/gal (CFw w) $0.005439 26. Pump Cost Factor, $/gpm (CFp) $23.64 27. Cost Factor for Caustic, $/ton (CFcaus) $600

## Ap **pendix D: Packed Bed Scrubber**

**Parameters/Costs Equation** 

28. Moles of caustic/moles pollutant (SR1) defined in Appendix D-2 

### 29. Caustic mole weight, lb/lbmole (MW caustic) defined in Appendix D-2 

### 30. Gas molecular weight, lb/lb-mole (MW g) defined in Appendix D-2 

### 31. Moles salt/moles HCl (SR2) defined in Appendix D-2 

### 32. Salt molecular weight, lb/lbmole (MW salt) defined in Appendix D-2 

### 33. Fraction of waste stream treated (BF) defined in Appendix D-2 

### 34. Maintenance labor rate, $/hr (Cfmain) $51.26 35. Retrofit Factor 1.4 19. Gas transport velocity, ft/min (ut) defined in Appendix D-2 

### 20. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2 

### 21. Number of Duct Lines, (ND) if Q < 154042 acfm =1 if Q > 154042 acfm = Q/154042 acfm 22. Length of ductwork (L) defined in Appendix D-2 

### 23. # of elbows per length of duct (Ne/Ld) defined in Appendix D-2 

### 24. Fan coefficient (af) defined in Appendix D-2 

### 25. Fan Diameter, inches (Df) defined in Appendix D-2 

### 26. Fan exponent (b) defined in Appendix D-2



### B. Total Capital Investment (TCI)

1. TCItower, $ =(417.956 x m x PI x Ds x Hpack) + (453.7808 x m x PI x Ds^2) + (838.8974 x m x PI x Ds) 2. TCIp, $ =0.649 x Cp x Hpack x PI x Ds^2 3. TCIpump, $ =0.0312 x MW R x a x PI x Ds^2 x Cfpump x m 4. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x (Df^b)))) 5. Total TCI, $ = (TCItower + TCIpump + TCIp + TCIduct) x (525.4/389.5) x Retrofit Factor 6. $/acfm = $ / Q

C. Direct Annual Operating Costs, $/yr

1. Electricity a. Pressure of pump, ft of H2O (Pp) defined in Appendix D-2 

### b. Efficiency of pump (Ep) defined in Appendix D-2 

### c. Electricity for Pump use, kw (Epump) =(0.00000585 x H x PI x Ds^2 x MW R x ap x Pp) / Ep 

### d. Friction loss factor for elbow (k) defined in Appendix D-2 

### e. Efficiency of fan (ef) defined in Appendix D-2 

### f. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x (ut/4016)^2) g. packing constant (c) defined in Appendix D-2 

### h. packing constant (j) defined in Appendix D-2 

### i. Pressure drop through scrubber, in.H2O (Ps) =(Hpack x AQ^2 x c x Dg x [10^(j x MW R x Dl x ap / 3600)]) / (225 x PI^2 x Ds^4)


### j. Pressure drop of gas, in.H2O (Pg) =Ps+Pd k. Electricity for Fan use, kW (Efan) =((0.000117 x AQ x H x Pg)/ef) l. Cost of Electricity, $/yr (Ce) =EC x (Epump + Efan) 2. Caustic Cost ($/yr), Ccaustic =0.03 x AQ x Dg x (In HClm - Out HClm) x SR1 x MW caustic x H x CFcaus / MW g 3. Cost of w

w disposal, $/yr (Cw

w) =7.194 x AQ x Dg x (In HClm - Out HClm) x SR2 x Mwsalt x (1/BF) x H

x CFww / MW g 4. Cost of water, $/yr (Cw) =Cw w x (CFw

/ CFw w) 5. Cost of Labor, $/yr (Clab) = 0.07188 x H x Cflab 6. Cost of Maintenance, $/yr (Cmain) =0.125 x H x Cfmain
D. Indirect Annual Costs, $/yr

1. Overhead = 0.6 x (CFlab + CFmain) 2. Property taxes = 0.01 x TCI 3. Capital recovery = Equipment CRF x (TCI) 4. Administrative cost =0.02 x TCI 5. Insurance =0.01 x TCI 6. Capital recovery = CRF x TCI 7. Duct TAC a.TACductwork =TCIduct x (0.04 + CRFduct)

## Ap **pendix D: Packed Bed Scrubber**

**Parameters/Costs Equation** 

b. Duct_cap recov =TACductwork x 0.7 c. Duct_admin =TACductwork x 0.1498 d. Duct_prop tax =TACductwork x 0.0749 e. Duct_insurance =TACductwork x 0.0749 f. Total TACduct =Duct_cap recov + Duct_admin + Duct_prop tax + Duct_insurance

E. Total Annual Cost

1. $/yr = Direct Annual Costs + Indirect Annual Costs + Total TACduct 2. ($/yr) / acfm = ($/yr) / AQ

Sources: 1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 8. EPA/452/B-02-001, January 2002. 2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process Heaters National Emission Standards for Hazardous Air Pollutants, October 2002.

# Ap **pendix D: Packed Bed Scrubber**

**Var COMMON DEFAULTS - PACKED SCRUBBER**  I I = interest rate 0.07 Dg Dg = density of gas, lb/ft3 0.0709 Ne_Ld Ne/LD = # of elbows per length of duct 0.02 L L = length of ductwork 500 MW R MW R = minimum wetting rate, ft2/hr 1.3 ut ut = gas transport velocity, ft/min 3000 Dl Dl = density of liquid, lb/ft3 62.4 ap a = packing constant, ft2/ft3 28

**Var DEFAULTS- TOTAL ANNUAL COST -- PACKED SCRUBBER** 

n n = life of equipment, yrs 15 SR1 SR1 = moles caustic/moles pollutant 0.5 MW c MW c = caustic molec wt, lb/lb-mole 62 Op_Scr Op_Scr = operating hours/year 8400 CFc Cfc = cost factor for caustic, $/ton 440 MW g MW g = gas molecular weight, lb/lb-mole 29 SR2 SR2 = moles salt/moles HCl 1 MW s MW s = salt molecular weight, lb/lb-mole 58.5 BF BF = fraction of waste stream treated 0.1 CFww CFww = cost factor for ww disposal, $/gal 0.0054 CFwt CFwt = cost factor for water, $/gal 0.00060 SR3 SR3 = adjustment for 76% Na2O solution 0.76 CFlab CFlab = cost factor for labor, $/hr 51.26 CFmain CFmain = cost factor for maintenance, $/hr 51.26

**DEFAULTS - ELECTRICITY - PACKED SCRUBBER** CFelec CFelec = cost factor for electricy, $/kw-hr 0.06998 Pp Pp = pressure of pump, ft of H20 60 Ep Ep = efficiency of pump 0.7 Op_pump Op_pump = operating hours/year 8000 cpc cpc = packing constant 0.24 j j = packing constant 0.17 k k = friction loss factor for elbow 0.35 ef ef = efficiency of fan 0.7

**DEFAULTS - DUCTWORK - PACKED SCRUBBER** af af = fan coefficient 22.1 b b = fan exponent 1.55 Df Df = fan diameter, inches 36.5 n_duct n_duct = life of equipment, yrs 20 **PA CKED SCRUBBER DEFAULTS** 

# Ap **pendix D: Packed Bed Scrubber**
**DEFAULTS -TCI - PACKED SCRUBBER**

m m = factor to convert from FRP to other material 1

mm mm = ratio of solvent density to water density 1 Fp Fp = packing factor 65 ui ui = viscosity of liquid, lb/ft-hr 2.16 f f = flooding factor 0.7 ug ug = viscosity of gas, lb/ft-hr 0.044 Dfg Dfg = diffusivity of pollutant in gas, ft2/hr 0.725 Dfl Dfl = diffusivity of pollutant in liquid, ft2/hr 0.000102 AFT AFT = absorption factor 17

x x = packing constant 3.82 t t = packing constant 0.0125 g g = packing constant 0.45 BBB BBB = packing constant 0.41 bb b = packing constant 0.22 eff eff = efficiency of scrubber 99 Cp Cp = packing cost factor, $/ft3 20 CFpump CFpump = cost factor for pump, $/gpm 23.64 Site Site 0 Bldg Bldg 0

Sources:

2. Oommen, Roy. Methodology for Estimating Control Costs for the Industrial, Commercial, and Institutional Boilers and Process Heaters National Emission Standards for Hazardous Air Pollutants, October 2002. 1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 8. EPA/452/B-02-001, January 2002.

## Ap **pendix E: Increased Caustic**
**Parameters/Costs Equation**  **Fuel Category F-Factor**  Bagasse 9420 A. Parameters Coal 9780

1. Annual operating hours, hr/yr (H) used Boiler Survey data as input Dry Biomass 9240 2. Exhaust gas flow rate, acfm (AQ) calculated per boiler, see Section 2.0 of the memo. Gas 1 8710 3. Exhaust gas flow rate, dscfm (Q) calculated per boiler, see Section 2.0 of the memo. Gas 1 - Metal Furnace 8710 4. Baseline HCl, units (lb/mmBtu) (HClb) calculated per boiler Heavy Liquid 9190 5. Floor HCl level, (lb/mmBtu) (HClf) assigned by fuel category Light Liquid 9190 6. F-Factor determined by fuel category, see index Non-Continental Liquid 9190 7. Uncontrolled HCl, ppmvd (HClu) =HClb x F-Factor x (1/36.4609) x 385.34 x 1000000 Process Gas 8710 8. Controlled HCl, ppmvd (HClc) =HClf x F-Factor x (1/36.4609) x 385.34 x 1000000 Wet Biomass 9600 9. Operating Labor Rate, $/hr (LR) $51.26 10. W astewater Blowdown, gpm (B) =Hclu/1000000 x Q x 1/385 x 1/1 x 58.2/1 x 1/0.1 x 1/8.33 11. Caustic Cost, $/ton (CC) $357 12. Sewage disposal, $/1000 gal (SDC) $5.40 13. W ater Cost, $/1000 gal (W C) $0.60 14. Lime Cost, $/ton (LC) $95 15. Sodium Bicarbonate, $/ton (SBC) $440 16. Dust Disposal, $/ton (DDC) $34.29 17. Activated Carbon, $/lb (ACC) $1.38 18. Natural Gas, $/1000 ft3 (NGC) $9.58 19. Electricity Cost, $/kW h (EC) $0.07 20. Capital recovery factors = [i x (1 + i) a] / [(1 + i) a - 1], where i = interest rate, a = equipment life a. Bag CRF, 2-yr life, 7% interest b. Cage CRF, 4-yr life, 7% interest 15. Cost index a. 2008 525.4 b. 1984 317.4

B. Total Bag/Cage Cost

1. $ = AQ x 2.5 x (525.4/317.4) x (1.08/3.5) 2. Bag Replacement Labor Cost = AQ x 0.15/18/3.5 x LR 3. Cage Replacement Labor Cost = Bag Replacement Labor Cost 4. Total Cage Cost = Cage CRF x ((4.941 + 0.163 x 18) x (AQ/3.5/18) x (5.75.4/317.4) + Cage Labor Cost

C. Total Increased NaHCO3 Cost

1. Makeup NaHCO3 Cost, $ = 2.73x10-7 x Hclu x Q x 1/2000 x 60 x H x SBC 2. Dust Disposal Cost, $ =HCLu x Q x 60 x 2.1x10-7 x 1/2000 x H x DDC 3. Total Cost, $/yr/dscfm =(Makeup NaHCO3 + Dust Disposal Cost) /Q

D. Increased Carbon Cost

1. Activated Carbon Cost, $ =1.27x10-3 x Q x H x ACC 2.Dust Disposal Cost, $ =1.27x10-3 x Q x 1/2000 x H x DDC 3. Total Cost, $/yr/dscfm = (Activated Carbon Cost + Dust Disposal Cost)/Q

Sources: 1. Cost equations: Hospital/Medical/Infectious W aste Incinerators (HMIW I) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (II-A-112); and Dry Injection Fabric Filter Cost Memorandum (IV-B-32).

## Appendix F: Activated Carbon Injection Model Costs **Equation**

A. Parameters **For fly ash waste rate calcs:**  1. Boiler design capacity, Btu/hr (C) used Boiler Survey data as input **Fuel Category Coal Type**  **HHV (Btu/lb)**  **Ash content**
2. Exhaust gas flow rate, dscfm (Q) calculated per boiler, see Section 2.0 of the memo. Bagasse N/A 4000 0.017 3. Annual operating hours, hr/yr (H) used Boiler Survey data as input Coal Bituminous 11000 0.12 4. Carbon cost, $/ton (Ca) = 1500 Coal Sub-Bituminous 8400 0.06 5. W aste disposal cost, $/ton (W D) = 42.14 Dry Biomass N/A 8623 0.031 6. Higher heating value, Btu/lb (HHV) fuel specific, see table to right Gas 1 - Metal Furnace N/A

-- 0 7. Ash content of fuel, % (A) fuel specific, see table to right Gas 1 N/A

-- 0 8. Boiler ash removal, % (AR) = .2 Heavy Liquid N/A 18990 0.005 9. Carbon feed rate, lb/hr (CF) If boiler equipped with fabric filter, then CF = Q x (60 min/hr) / (1,000,000 acf/MMacf) x (2 lb/MMacf) If boiler is not equipped with fabric filter, then CF = Q x (60 min/hr) / (1,000,000 acf/MMacf) x (5 lb/MMacf) Light Liquid N/A 19750 0 10. Carbon waste rate, lb/hr (CW ) = CF Non-Continental Liquid N/A 18990 0.005 11. Fly ash waste rate, ton/hr (FAW ) = C / (HHV) / (2000 lb/ton) x A x (1 - AR) Process Gas N/A

-- 0 12. Total waste rate, ton/hr (TW ) = FAW + (CF / (2000 lb/ton)) Wet Biomass N/A 8623 0.031 13. Capital recovery factor, 20-yr equipment life, 7% interest (CRF) = [i x (1 + i) a] / [(1 + i) a - 1], where i = interest rate, a = equipment life

Notes: B. Total Capital Investment - For liquids the maximum HHV and ash values are used 1. Base cost, $ (BC) = 1,350,000 x (CF 0.15 ) - For wet and dry biomass the average of all four biomass ty pes is used 2. Engineering and Construction Management costs, $ (ECM) = 0.05 x BC

3. Labor adjustment for 6 x 10 hour shift premium, per diem, etc., $ (LA) = 0.05 x BC
4. Contractor profit and fees, $ (CP) = 0.05 x BC

**Parameters/Costs**

Source: Babcock and W ilcox. Steam its generation and use 40th edition. Pgs 8-10, 8-15, 8-18. 1992. 4. Contractor profit and fees, $ (CP) = 0.05 x BC 5. Capital, Engineering and Construction Cost Subtotal (CEC) = BC + ECM + LA + CP
6. Owners costs, $ (OC) = 0.05 x CEC 7. Total capital, $ (TCI) = CEC + OC

C. Annual Cost - Fixed O&M 1. Maintenance material and labor, $/yr (MML) = 0.005 x TCI 2. Administrative labor, $/yr (AL) = 0.03 x 0.4 x MML 3. Total fixed O&M, $/yr (FOM) = MML + AL + (CRF x TCI)

D. Annual Cost - Variable O&M 1. Carbon sorbent, $/yr (CS) = CF x Ca x H / (2000 lb/ton) 2. W aste disposal $/yr (W D) = TW x W D x H 3. Total variable O&M, $/yr (VOM) = CS + W D

E. Total Annual Cost 1. $/yr = FOM + VOM

Sources:

3. Dust disposal cost: NSW MA’s 2005 Tip Fee Survey. 2. Activated carbon cost: The Innovation Group. Chemical Profiles: Carbon, Activated. 2002. Assumed 20% price increase based on 1. Sargent & Lundy, IPM Model – Revisions to Cost and Performance for APC Technologies: Mercury Control Cost Development Methodology (Project 12301-009). March 2011. 1992.

# Ap **pendix F: A ctivated Carbon Injection Model Costs** 

**Equation**

A. Parameters 1. Capital recovery

factor, 20-yr equipment life, 7% interest (CRF) = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipment life

B. Total Capital Investment 1. Slurry additive base cost, $ (SLA) = 500,000 2. Engineering and Construction Management costs, $ (ECM) = 0.05 x SLA

3. Labor adjustment for 6 x 10 hour shift premium, per diem, etc., $ (LA) = 0.05 x SLA
4. Contractor profit and fees, $ (CP) = 0.05 x SLA 5. Capital, Engineering and Construction Cost Subtotal (CEC) = SLA + ECM + LA + CP

6. Owners costs, $ (OC) = 0.05 x CEC 7. Total capital, $ (TCI) = CEC + OC

C. Annual Cost - Fixed O&M 1. Maintenance material and labor, $/yr (MML) = 0.005 x TCI 2. Administrative labor, $/yr (AL) = 0.03 x 0.4 x MML 3. Total fixed O&M, $/yr (FOM) = MML + AL + (CRF x TCI)

D. Annual Cost - Variable O&M 1. Slurry additive system O&M, $/yr (VOM) = 115 x H **Parameters/Costs If boiler has SCR A** **ND WET FGD is installed for HCl reduction, A ND the boiler needs a Hg reduction of less**  **than 80% A ND the coal is Bituminous -then A** **CI w ould not be costed, BUT Slurry**  **A dditives are.** 

E. Total Annual Cost 1. $/yr = FOM + VOM

Sources: 1. Sargent & Lundy , IPM Model – Revisions to Cost and Performance for APC Technologies: Mercury Control Cost Development Methodology (Project 12301-009). March 2011.

## Ap **pendix F: A ctivated Carbon Injection Model Costs** 

**Equation**

A. Parameters 1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input 2. Capital recovery factor, 20-yr equipment life, 7% interest (CRF) = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipment life

B. Total Capital Investment 1. Slurry additive base cost, $ (SLA) = 500,000 2. Halogen additive system, $ (HA) = 1,000,000 3. Engineering and Construction Management costs, $ (ECM) = 0.05 x (SLA + HA)

4. Labor adjustment for 6 x 10 hour shift premium, per diem, etc., $ (LA) = 0.05 x (SLA + HA)
5. Contractor profit and fees, $ (CP) = 0.05 x (SLA + HA) 6. Capital, Engineering and Construction Cost Subtotal (CEC) = SLA + HA + ECM + LA + CP
7. Owners costs, $ (OC) = 0.05 x CEC 8. Additive royalty fee, $ (ARF) = 2500 x C x (1 kW / 0.00344 mmBtu/hr) / (1000 kW / 1 MW ) 9. Total capital, $ (TCI) = CEC + OC + ARF

C. Annual Cost - Fixed O&M 1. Maintenance material and labor, $/yr (MML) = 0.005 x TCI 2. Administrative labor, $/yr (AL) = 0.03 x 0.4 x MML 3. Total fixed O&M, $/yr (FOM) = MML + AL + (CRF x TCI)

D. Annual Cost - Variable O&M 1. Slurry additive system O&M, $/yr (SAVOM) = 115 x H 2. Halogen additive system O&M, $/yr (HAVOM) = 290 x H 3. Total variable O&M, $/yr (VOM) = SAVOM + HAVOM **If boiler has SCR AND WET FGD is installed for HCl reduction, AND the boiler needs a Hg reduction of less than 80% AND the**  **coal is Sub-bituminous or Lignite -then ACI would not be costed, BUT Halogen Addition and Slurry Additives are.**

**Parameters/Costs**

E. Total Annual Cost 1. $/yr = FOM + VOM

Sources: 1. Sargent & Lundy, IPM Model – Revisions to Cost and Performance for APC Technologies: Mercury Control Cost Development Methodology (Project 12301-009). March 2011.

## Ap **pendix G: Low NOx Burners** 

**Parameters/Costs Equation** 

A. Parameters

1. Boiler design capacity , mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr) 

### 2. Annual operating hours, hr/yr (H) used Boiler Survey data as input 

### 3. Unit Size, kW (kW ) =C x (1000/3.413) 

### 4. Unit Size, MW (MW ) =C x (1/3.413) 

### 5. Capital recovery

factor = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipm ent life a. Equipment CRF, 15-yr life, 7% interest

15. Cost index a. 2008 525.4 b. 2004 444.2

B. Total Capital Investment

TCI ($) =20 x kW x (300/MW )^0.359
C. Direct Annual Operating Costs, $/yr

Variable O&M Costs = 0.000293 x H x C x (0.05/1000) x (575.4/444.2)

D. Indirect Annual Costs, $/yr

1. Fixed O&M Costs = 0.015 x TCI 2. Capital recovery = Equipm ent CRF x TCI

1. $/yr = Direct Annual Costs + Indirect Annual Costs

Source:

1. ERG, 2005. Analysis of Combustion Controls for Reducing NOx Emissions from Coal-Fired EGUs in the WRAP Region September 6, 2005.

## Appendix H: Oxidation Catalyst

**Parameters/Costs Equation** 

A. Parameters 1. Boiler design capacity, mmBtu/hr (C) used Boiler Survey data as input, for small units (<10, used 5 mmBtu/hr) 2. Annual operating hours, hr/yr (H) 8400 3. Exhaust gas flow rate, scfm (Q) calculated per boiler, see Section 2.0 of the memo. 4. Percent additional fuel/air added (Aux) = Default of 0.05 5. Exhaust gas flow rate, scfm (AF) =Q x (1+Aux) 6. Equipment Cost, $ (EC) = 1105 x Q^0.5471 7. Additional Purchase Equipment Cost (Instruments,taxes,freight), $ (AddEC) = 0.35 x EC
8. Direct Installation Costs, $ (DIC) =0.282 x (EC+AddEC) 9. Indirect Installation Costs, $ (IIC) =0.22 x (EC + AddEC) 9. Operating labor rate, $/hr (LR) 51.26 10. Electricity cost, $/kW h (EC) 0.06998 11. Catalyst cost, $/ft^3 (Cc) 959 12. Pressure change, in of H2O (Pc) 6 13. Efficiency of fan and motor (Ef) 0.6 14. Capital recovery factors = [i x (1 + i) a

### ] / [(1 + i) a 

### - 1], where i = interest rate, a = equipment life a. Catalyst CRF, 2-yr life, 7% interest b. Equipment CRF, 20-yr life, 7% interest 15. Cost index a. 2008 525.4 b. 1990 390.6

16. Space Velocity in 1/h (Sv) 12000

17. Retrofit Factor 1.4

Total Capital Investment B. 1. $ =(EC + AddEC + DIC + IIC) x (577.4/390.6) x Retrofit Cost

2. $/scfm = $ / Q
C. Direct Annual Operating Costs, $/yr 1. Electricity a. Power of Fan (Pf) =(0.000117 x AF x Pc)/0.6 b. Cost of Electricity =Pf x H x EC 2. Operating labor = H/8 x 0.5 x LR 3. Supervisory labor = 0.15 x (operating labor) 4. Maintenance labor = Operating labor 5. Maintenance materials = Maintenance labor 6. Catalyst Replacement a. Catalyst Replacement Volume, ft3 (CRV) =AF x 60/Sv b. Catalyst Replacement Cost =CRV x Cc x Catalyst CRF

## Appendix H: Oxidation Catalyst

**Parameters/Costs Equation**  1. Overhead = 0.6 x (electricity + operating labor + supervisory labor + maintenance labor + maintenance materials + catalyst replacement) D. Indirect Annual Operating Costs, $/yr 2. Property taxes, insurance, and administration = 0.04 x TCI

3. Capital recovery = Equipment CRF x (TCI - 1.08 x catalyst replacement cost)

E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs 2. ($/yr) / dscfm = ($/yr) / Q

Sources: 1. U.S. Environmental Protection Agency, EPA Air Pollution Control Cost manual, Sixth Edition. Chapter 2. EPA/452/B-02-001, January 2002.

### Appendix I: Dry Injection Fabric Filter Costs **Parameters/Costs Equation** 

A. Parameters 1. Boiler design capacity , mmBtu/hr (C) used Boiler Survey data as input 2. Annual operating hours, hr/yr (H) used Boiler Survey data as input 3. Exhaust gas flow rate, dscfm (Q) calculated per boiler 4. HCl concentration, ppmvd (HCl) used Boiler Survey data as input 5. PM concentration, gr/dscf (PM) calculated baseline emission factor using Boiler Survey data as input: (lb/mmBtu)*C*(7000/60)/Q 6. W ater vapor in gas (% by weight) (%M) a. lb/min = Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x %M b. scfm = (lb/min) / (18 lb/lb-mol) x (385 ft3/lb-mol)

a. Dry gas from boiler, Btu/lb air = [7.010 x (300 ° F - 77 ° F) - 7.554 x (1800 ° F - 77 ° F)] / (29 lb/lb-mol) b. W ater vapor from boiler, Btu/lb water vapor = [8.154 x (300 ° F - 77 ° F) - 9.215 x (1800 ° F - 77 ° F)] / (18 lb/lb-mol) c. Total gas stream, Btu/yr = [(Btu/lb air) x Q / (385 ft3/lb-mol) x (29 lb/lb-mol) x (60 min/hr) x H] + [(Btu/lb water vapor) x Q x (0.00753 lb water vapor/ft3 ) x (60 min/hr) x H] d. Cooling water i. Heat of vaporization at 77 ° F, Btu/lb 1,050 ii. Sensible heat for vapor, Btu/lb 85 iii. Total, Btu/lb water 1,135 8. Cooling water evaporated, lb/yr a. lb/yr = [enthalpy change (total gas stream, Btu/yr)] / [enthalpy change (cooling water, Btu/lb)] b. scfm = [cooling water evaporated (lb/yr)] / (18 lb/lb-mol) x (385 ft3/lb-mol) / (H * 60 min/hr) 9. Actual gas flow into fabric filter, acfm (AQ) = [Q + (water vapor in gas from incinerator, scfm) + (water vapor added in quench, i.e., cooling water evaporated, scfm)] x [(300 ° F + 460 ° F)/528 ° R] 10. Operating labor rate, $/hr (LR) $51 11. Electricity

cost, $/kW h (EC) $0.069981 12. Lime cost, $/ton (LC) $95 13. W ater cost, $/1,000 gal (W C) $0.20 14. Compressed air cost, $/1,000 ft3(CAC) $0.31 15. Dust disposal cost, $/ton (DDC) $42.14 16. Capital recovery

factors (CRF) = [i x (1 + i) a] / [(1 + i) a - 1], where i = interest rate, a = equipment life a. Bag CRF, 2-yr life, 7% interest 0.55309 b. Cage CRF, 4-yr life, 7% interest 0.29523 c. Equipment CRF, 20-yr life, 7% interest 0.09439 17. Cost index a. 2008 575.4 b. 1989 357.5 18. Retrofit Factor 1.4 19. Gas transport velocity , ft/min (ut) assigned constant, 3000 20. Diameter of duct, ft (Dd) =1.128 x (Q/ut)^1/2 21. Number of Duct Lines, (ND) if Q < 154042 acfm =1 if Q > 154042 acfm = Q/154042 acfm 22. Length of ductwork (L) assigned constant, 500 23. # of elbows per length of duct (Ne/Ld) assigned constant, 0.02 24. Fan coefficient (af) assigned constant, 22.1 25. Fan Diameter, inches (Df) assigned constant, 36.5 26. Fan exponent (b) assigned constant, 1.55 B. Total Capital Investment 1. TCIduct, $ =(1.458 x ((0.39 x ((Dd/ND)^2) x 3.14159 x L)+(74.2 x L x Ne/Ld x EXP(0.8016 x (Dd/ND))) + (23 x EXP(0.6804 x (Dd/ND))) + (af x (Df^b))))*(575.4/389.5) 2. TCI, $ = (63.8 x Q + 407,498) x (1.4 retrofit cost factor) x (575.4/357.5)+TCIduct 3. $/dscfm = TCI / Q
C. Direct Annual Operating Costs, $/yr 1. Electricity = (0.746 kW /hp) x hp (0.0079 x Q + 3.51) x H x EC 2. Makeup lime = (2.4E-7 lb/dscf x HCl x Q) x (1 ton/2,000 lb) x (60 min/hr) x H x LC 3. Evaporative cooler water = (0.1007 x Q + 23.1506) gal/min x (60 min/hr) x H x W C 4. Operating labor = (1 hr/shift) x (1 shift/8 hr) x H x LR 5. Supervisory

labor = 0.15 x (operating labor) 6. Maintenance labor = (0.5 hr/shift) x (1 shift/8 hr) x H x (LR x 1.1) 7. Maintenance materials = 0.02 x TCI 7. Enthalpy

change in quench (1800 ° F to 300 ° F)

### Appendix I: Dry Injection Fabric Filter Costs

8. Compressed air = AQ x (2 ft3air/1,000 ft3filtered) x (60 min/hr) x H x CAC 9. Dust disposal = [(PM gr/dscf x Q x 60 min/hr x 1 lb/7,000 gr) + (HCl x Q x 60 min/hr x 2.86E-7 lb/dscf)] x (1 ton/2,000 lb) x H x DDC 10. Bag replacement a. Bag cost = AQ x ($2.5/ft2 ) x (575.4/317.4) x (1.08 taxes and freight ratio)/(3.5 ft/min G/C ratio) b. Bag replacement labor cost = AQ x (0.15 hr/bag)/(18 ft2bag area)/(3.5 ft/min G/C ratio) x LR c. Bag replacement cost = Bag CRF x [(total bag cost) + (bag replacement labor cost)] 11. Cage replacement a. Number of bags = AQ/(3.5 ft/min G/C ratio)/(18 ft2bag area) b. Cage replacement labor cost = bag replacement labor cost c. Cage replacement cost = Cage CRF x [single-cage cost (4.941+ 0.163 x 18 ft2bag area) x (number of bags) x (575.4/317.4) + (cage replacement labor cost)] 12. Electricity

of Fans a. Friction loss factor for elbow (k) assigned constant, 0.19 b. Efficiency

of fan (ef) assigned constant, 0.70 c. Pressure drop through duct, in.H2O (Pd) =0.136 x (1/Dd)^1.18 x (ut/1000)^1.8 + (L/100) x (L x Ne/Ld x k x (ut/4016)^2) f. Electricity for Fan use, kW (Efan) =((0.000117 x Q x H x Pd)/ef) g. Cost of Electricity, $/yr =EC x Efan D. Indirect Annual Costs, $/yr 1. Overhead = 0.6 x (labor + maintenance materials) 2. Property taxes, insurance, and administration = 0.04 x TCI 3. Capital recovery = Equipment CRF x (TCI - bag replacement cost - cage replacement cost)

E. Total Annual Cost 1. $/yr = Direct Annual Costs + Indirect Annual Costs 2. ($/yr) / dscfm = ($/yr) / Q

Sources:

3. Electricity cost: Energy Information Administration. Average Retail Price of Electricity : 2006. 4. Lime cost: U.S. Geological Survey . Mineral Commodity Summaries 2008. Hydrated Lime Average Value, 2007. 5. W ater cost: Air Compliance Advisor, version 7.5. 6. Compressed air cost: P2Pays.org. Energy Tips – Compressed Air. Compressed Air Tip Sheet #1. August 2004. 7. Dust disposal cost: NSW MA’s 2005 Tip Fee Survey

. 2. Operating labor rate: Bureau of Labor Statistics, Occupational Employment Statistics, May 2007 National Industry-Specific Occupational Employment and W age Estimates 1. Cost equations: Hospital/Medical/Infectious W aste Incinerators (HMIW I) [EPA-HQ-OAR-2006-0534] Model Plant Description and Cost Report (IIA-112); and Dry

Injection Fabric Filter Cost Memorandum (IV-B-32).

### Ap **pendix J-1: Summary of Testing Costs**

Liquid Fuel? Cost per Testing Trip Pollutants Tested For

no 28000 CO, PM, HCl, Hg
yes 11000 CO, PM



### Notes:
**Testing:**
Testing Costs were estimated by E RG Air Laboratory

S taff in March 2009 and September 2011 and assume that the testing contractor will ma ke a single trip to the facility to conduct all necessary tests.
A basic range of testing costs was applied to various pollutants. Tests for PM (filterable), CO, and HCl could be completed with manual testing methods, and these manual methods were estim ated to range from approximately $5,000

- $7,000. For the tests that involve mo re lab analysis (e.g., Hg), the testing costs were estimated to range from approxim ately $10,000

- $15,000.

Although these cost ranges can be applied as is for cases where a single pollutant is being measured, estimating costs for facilities that need test data for more than one pollutant is more difficult and uncertain. For example, if a facility n eeds PM data and CO data, the test costs would not be twice the $5,000

- $7,000 range because some of the costs are associated with getting to the site and setting up the equipment. Such costs are one

-tim e costs and would not be duplicated no m atter how many pollutants are to be tested). Therefore, if a facility h ad more than one of the simpler tests to run (e.g., PM and CO or PM and HCl), then the site

- specific cost would start in the $5,000

- $7,000 with a few $1,000 added for subsequent pollutants. If a facility n eeded PM data and mercury data, then the site

- specific cost would be the sum of the test in the $5,000

- $7,000 range and the $10,000

- $15,000 range.
For liquid fuels, it was assumed that units would com ply using a fuel analysis (or by receiving a certified fuel analysis from the fuel supplier for HCl and Hg), so the costs for these two tests for Hg and HCl were subtracted from the total testing costs.
**Repeat Testing:**
Provisions in the rule require facilities to identify t he worst case fuel or fuel mixture for both chlorine and mercury

. Many commenters noted that this would require multiple performance tests because the worst case fuel for chlorine is not necessarily the worst case fuel for mercury . EPA estim ated repeat testing costs for HCl and Hg only at $18,000.

### Analy

zers BEFORE AFTER CO 0 1 SO2 0 0 NOX 0 0 HCl 0 0 Mercury

(and CO2/O2) 0 0 CO2 0 0 O2 0 0 THC 0 0 Sum ma ry

of Costs

First Costs Labor Test ODCs Total Planning 4,835 0 352 5,187 Select Equipment 20,313 0 3,067 23,380 Support Facilities 0 0 19,065 19,065 Purchase CEMS Hardware 0 0 61,070 61,070 Install and Check CEMS 6,534 0 11,979 18,513 Performance Specification Tests 3,907 11,230 503 15,640 QA/QC Plan 4,679 14,546 692 19,917 40,269 25,777 96,727 162,773 TCI

Annual Costs Day-to-Day

Activities 7,503 0 1,000 8,503 Annual RATA 1,337 10,642 0 11,980 PM Monitor RCA 0 0 0 0 PM Monitor RRA 0 0 0 0 Cylinder Gas Audits (ACA/SVA for PM) 2,034 0 1,069 3,103 Recordkeeping and Reporting 1,822 0 160 1,982 Annual QA & O&M Review and Update 3,399 0 1,161 4,560 Capital Recovery (i=7%, monitor life = 10 years) 

### 5,734 3,671 13,774 23,179

Total w/o capital recovery 16,095 10,642 3,390 30,128 Total with capital recovery 21,830 14,313 17,164 53,307 TAC

Source: U.S. EPA CEMS Cost Model. 03/07/2007. http://www.epa.gov/ttn/em c/cem.html **Ap pendix J-2: Summary of CO CEMS** **Appendix J-3: Other Monitoring Costs for Boilers and Process Heaters Parameters/Costs**  **Equation**

**A. Parameters**

1. Recording lime/carbon flow, min/4- hr period 5 5

2. Annual operating hours, hr/yr (H)

3. Cost index a. 2008 575.4 575.4 575.4 575.4 All costs are in $2008 575.4 575.4 575.4

b. 2006 499.6 All costs are in $2006 499.6 All costs are in $2006 499.6 All costs for FF are in $2006

c. 2002 395.6 All costs are in $2002

d. 1998

389.5 All costs are in $1997

e. 1997 386.5 All other costs are $1997 386.5 All other costs are $1997 f. 1993 359.2 Equipment costs, are $1993 359.2 Equipment costs, are $1993 g. 1992 4. Operating labor wage rate, $/hr (LR) $34.60 $34.60 $34.60 $34.60 $51.26

5. Capital recovery factor, 20-yr equipment life, 7% interest (CRF) = [i x (1 + i) a] / [(1 + i) a - 1], where i = interest rate, a = equipment life 0.09439 0.09439 0.09439 0.09439 0.09439

**B. Total Capital Investment, $ (TCI)**

1. Planning $700 $800 $900 $1,500 2. Select type of equipment $400 $4,500 $12,200 $4,900 3. Provide support facilities $1,500 $500 $500 $2,000 4. Purchased equipment cost (PEC) $19,300 $14,100 $73,500 $27,100

5. Install and check equipment $1,000 $4,800 $19,500 $5,800 6. Perf. spec. tests (certif.) $700 $0 $35,500 $700 7. Prepare QA/QC plan $700 $800 $15,400 $1,500 8. Total capital cost = Planning + selecting equipment + support facilities + PEC + installation + perf. spec. tests + QA/QC plan $24,300 $25,500 $158,000 $115,000 $43,137 $43,500 $8,523 **DIFF O2** 

**As reported in survey Opacity** 

**As reported in survey WS**  **Bag leak detector PM CEMS**  **ACI Appendix J-3: Other Monitoring Costs for Boilers and Process Heaters**  **DIFF O2**  **Opacity WS**  **Bag leak detector PM CEMS**  **ACI C. Annual Costs, $/yr** 

1. Operating labor = (5 min to record lime/carbon flow/4-hr period) x (1 hr/60 min) x H x LR 2. Maintenance materials = 0.02 x TCI $500 $1,477 3. Operation & maintenance = Day-to-day activities + annual RATA + CGA + annual QA + O&M review and update $6,000 $27,300

$5,909 4. Recordkeeping and reporting = $1,000 x (525.4/386.5) $1,500 $200 $6,300 $1,477 5. Overhead = 0.6 x (labor + maintenance materials) $300

6. Property taxes, insurance, and administration = 0.04 x TCI $1,000 $1,725 7. Capital recovery = CRF x TCI $2,300 $3,500 $22,500 $4,071 8. Total annual cost = Operating labor + maintenance materials + recordkeeping and reporting + overhead + property taxes, insurance, and administration + capital recovery $5,600 $9,700 $56,100 $14,661 $1,436

Notes: 1. Monitoring costs have been rounded to the nearest $100 to be consistent with level of rounding in original costs. 2. Costs to be replaced include: (a) bag leak detector replacing opacity test; (b) CO CEMS replacing CO test and secondary chamber temperature monitor; (c) HCl CEMS replacing HCl test, HCl sorbent monitor (dry scrubbers) and scrubber liquor pH monitor (wet scrubbers); (d) PM CEMS replacing PM and opacity tests and and pressure drop monitor (wet scrubbers); (e) multi-metal/Hg CEMS replacing flue gas temperature monitor (wet scrubbers); (f) dioxin sorbent trap biweekly monitoring replacing fabric filter inlet temperature monitor; and (g) Hg sorbent trap biweekly monitoring replacing flue gas temperature monitor (wet scrubbers).

Sources: 1. Hospital/Medical/Infectious Waste Incinerators (HMIWI) [EPA-HQ-OAR-2006-0534] Testing and Monitoring Options and Costs Memo (IV-B-66). 2. E-mail from Dan Bivins, EPA, to Mary Johnson, EPA. July 28, 2006. Some Preliminary Thoughts on the HWI Monitoring.

4. In Situ Oxygen Monitor Costs. EPA Air Pollution Control Cost Manual, Sixth Edition, January 2002, http://www.epa.gov/ttn/catc/dir1/c_allchs.pdf , Equipment cost from Table 4.11 (pg 180). Based on hrs/yr Based on hrs/yr

Based on hrs/yr

3. Memorandum from Thomas Holloway, Midwest Research Institute, to Rick Copland, U.S. Environmental Protection Agency, Revised Testing and Monitoring Options and Costs for Medical Waste Incinerators (MWI’s) - Methodology and Assumptions. March 17, 1997. Based on hrs/yr Based on hrs/yr

Based on hrs/yr